Thermoelectric converter

ABSTRACT

A thermoelectric converter includes a first substrate, a second substrate, a plurality of thermoelectric conversion elements, and a group of electrodes. The plurality of thermoelectric conversion elements are disposed between the first substrate and the second substrate. The group of electrodes electrically interconnect the plurality of thermoelectric conversion elements. The plurality of thermoelectric conversion elements are arranged in a plurality of rows including a first row and a second row. The first row is adjacent to the second row. The group of electrodes includes a first electrode and a second electrode having a different shape from the first electrode. The second electrode includes a first notch and a second notch each of which is disposed on an edge of the second electrode. The first notch is disposed to separate one of the plurality of thermoelectric conversion elements in the first row and one of the plurality of thermoelectric conversion elements in the second row.

CROSS REFERENCE OF RELATED APPLICATIONS

This application is the Continuation Application of U.S. applicationSer. No. 15/497,370 filed Apr. 26, 2017, now allowed, which claims thebenefit of Japanese Application No. 2016-122654 filed Jun. 21, 2016, theentire contents of each are hereby incorporated by reference.

BACKGROUND 1. Technical Field

The present disclosure relates to a thermoelectric converter thatconverts heat to electricity or electricity to heat.

2. Description of the Related Art

Thermoelectric converters have been conventionally used to cool or heatobjects. At present, thermoelectric converters are used to convertexhaust heat generated in factories and other facilities to electricity.A thermoelectric converter of this type includes a combination of manyp-type and n-type thermoelectric conversion elements that employ athermoelectric effect, such as the Seebeck effect, Peltier effect orThomson effect.

Unexamined Japanese Patent Publication No. 2002-111080 discloses athermoelectric converter in which many p-type and n-type thermoelectricconversion elements are arranged in rows between two substrates. In thisconfiguration, these p-type and n-type thermoelectric conversionelements are electrically interconnected by a group of electrodesmounted on each substrate. Some of the electrodes are disposed acrossadjacent rows of thermoelectric conversion elements and eachinterconnect four thermoelectric conversion elements, more specificallytwo p-type thermoelectric conversion elements and two n-typethermoelectric conversion elements mounted thereon. Remaining electrodesare each disposed along a single row of thermoelectric conversionelements and interconnect a corresponding pair of p-type and n-typethermoelectric conversion elements in series.

SUMMARY

A thermoelectric converter of the present disclosure includes a firstsubstrate being capable to deform, a second substrate being capable todeform, a plurality of thermoelectric conversion elements, and a groupof electrodes. The plurality of thermoelectric conversion elements aredisposed between the first substrate and the second substrate. The groupof electrodes electrically interconnect the plurality of thermoelectricconversion elements by solder bonding the plurality of thermoelectricconversion elements to the group of electrodes, respectively. Theplurality of thermoelectric conversion elements are arranged in aplurality of rows including a first row and a second row. The first rowis adjacent to the second row. The plurality of rows extend in anextending direction identical to each other. The group of electrodesincludes a first electrode and a second electrode having a differentshape from the first electrode. The first electrode electricallyinterconnects between two of the plurality of thermoelectric conversionelements in the first row. The second electrode electricallyinterconnects between one of the plurality of thermoelectric conversionelements in the first row and one of the plurality of thermoelectricconversion elements in the second row. The second electrode includes afirst notch and a second notch each of which is disposed on an edge ofthe second electrode. The first notch and the second notch are arrangedin a line extending between the first row and the second row. The firstnotch is disposed in a region sandwiched between a first part of thesecond electrode and a second part of the second electrode in plan view.The second notch is disposed away from the region sandwiched between thefirst part of the second electrode and the second part of the secondelectrode in plan view. The one of the plurality of thermoelectricconversion elements in the first row is disposed on the first part ofthe second electrode, and the one of the plurality of thermoelectricconversion elements in the second row is disposed on the second part ofthe second electrode.

According to the thermoelectric converter of the present disclosure,both the first substrate and the second substrate are capable to deform.The second electrode (the bridge electrode) includes a first notch and asecond notch each of which is disposed on an edge of the secondelectrode. And the first notch and the second notch are arranged in aline extending between the first row and the second row. Thus, thebridge electrode is easily bent at a line including the first notch andthe second notch. In addition, the thermoelectric converter is easilybent along and across the gap between adjacent rows. This enables afunctional surface of the thermoelectric converter to easily fit amounting surface.

According to the thermoelectric converter of the present disclosure, asdescribed above, the thermoelectric converter can cause its functionalsurface to easily fit the mounting surface without affectingcharacteristics of the thermoelectric converter.

Effects and significance of the present disclosure will be definite fromthe exemplary embodiment described below. It should be understood thatthe exemplary embodiment is one example for use in embodying the presentdisclosure and not intended to limit the present disclosure accordingly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating a configuration of athermoelectric converter according to an exemplary embodiment of thepresent disclosure, from which a second substrate is removed;

FIG. 2A is a plan view illustrating an arrangement of a group ofelectrodes on a first substrate in the thermoelectric converteraccording to the exemplary embodiment;

FIG. 2B is a plan view illustrating an arrangement of a group ofelectrodes on a second substrate in the thermoelectric converteraccording to the exemplary embodiment;

FIG. 3 is a partially enlarged view illustrating the arrangement of thegroup of electrodes on the first substrate in the thermoelectricconverter according to the exemplary embodiment;

FIG. 4A is a plan view illustrating an arrangement of thermoelectricconversion elements that are mounted on the group of electrodes on thefirst substrate in the thermoelectric converter according to theexemplary embodiment;

FIG. 4B is a plan view illustrating the arrangement of thethermoelectric conversion elements, relative to the arrangement of thegroup of electrodes on the second substrate in the thermoelectricconverter according to the exemplary embodiment;

FIG. 5 is a partially enlarged view illustrating interconnectionsbetween the thermoelectric conversion elements in the thermoelectricconverter according to the exemplary embodiment;

FIG. 6 is a perspective view illustrating the configuration of thethermoelectric converter according to the exemplary embodiment, to whichthe second substrate is attached;

FIG. 7A is a schematic view illustrating the thermoelectric converteraccording to the exemplary embodiment in a state before thethermoelectric converter is mounted on a mounting surface of an object;

FIG. 7B is a schematic view illustrating the thermoelectric converteraccording to the exemplary embodiment in a state after thethermoelectric converter is mounted on the mounting surface of theobject; and

FIG. 8 is a perspective view illustrating a configuration of athermoelectric converter according to a variation of the exemplaryembodiment, from which a second substrate is removed.

DETAILED DESCRIPTION OF EMBODIMENT

Prior to the description of an exemplary embodiment of the presentdisclosure, a problem with conventional thermoelectric converters willbe described below. A thermoelectric converter is not always mounted ona flat mounting surface. There are cases where a thermoelectricconverter is mounted on a curved or other arbitrary shaped mountingsurface. It is thus preferable that a thermoelectric converter can bedeformed so that its functional surface fits the mounting surface.However, in the thermoelectric converter configured as in UnexaminedJapanese Patent Publication No. 2002-111080, some electrodes are eachdisposed across adjacent rows of thermoelectric conversion elements, andremaining electrodes are each disposed along a single row ofthermoelectric conversion elements. This arrangement of thethermoelectric conversion elements may inhibit the thermoelectricconverter from being deformed in any given directions, includingvertical and horizontal directions. Therefore, if the thermoelectricconverter is mounted on a non-flat mounting surface, the functionalsurface may fail to fit the mounting surface. This makes it difficultfor the thermoelectric converter to provide high thermoelectricconversion efficiency.

The present disclosure, which addresses the above problem, provides athermoelectric converter that can be mounted on a non-flat mountingsurface with its functional surface easily fitting this mountingsurface.

Some exemplary embodiments of the present disclosure will be describedbelow with reference to the accompanying drawings. In every drawing, X,Y, and Z axes that are orthogonal to one another are depicted, for thesake of convenience. A Z-axis direction corresponds to a heightdirection of thermoelectric converter 100, and the positive side of theZ axis corresponds to the upward side.

FIG. 1 is a perspective view illustrating a configuration ofthermoelectric converter 100 from which second substrate 50 is removed.

Thermoelectric converter 100 includes first substrate 10, thermoelectricconversion elements 20, and support members 30.

First substrate 10 has a square contour with rounded corners, in planview. First substrate 10 is made of a material having highlythermally-conductive and deformable properties. As an example, firstsubstrate 10 may be made of a highly thermally-conductive and flexiblematerial. First substrate 10 may be a thin copper plate. As analternative example, first substrate 10 may be made of aluminum, asilicon resin, or an epoxy resin.

A group of electrodes including electrodes 11 and bridge electrodes 12,13 are provided on the positive side of first substrate 10 along the Zaxis, namely, on the upper surface of first substrate 10. Firstpatterned portions 14, 15, 16, 17 and second patterned portions 18, 19are provided on the periphery of the upper surface of first substrate10. Each of electrodes 11, bridge electrodes 12, 13, first patternedportions 14, 15, 16, 17, and second patterned portions 18, 19 may bemade of copper or aluminum, for example. If the first substrate 10 ismade of an electrically-conductive material, an insulating layer needsto be formed on first substrate 10 in order to electrically insulatesfirst substrate 10 from electrodes 11, bridge electrodes 12, 13, firstpatterned portions 14, 15, 16, 17, and second patterned portions 18, 19.In this case, the insulating layer may be formed between first substrate10 and each of electrodes 11, bridge electrodes 12, 13, first patternedportions 14 to 17, and second patterned portions 18, 19.

The lower surfaces of thermoelectric conversion elements 20 are bondedto the upper surfaces of electrodes 11 and the upper surfaces of bridgeelectrodes 12, 13 by a solder. The lower surfaces of support members 30are also bonded to the upper surfaces of second patterned portions 18,19 by a solder. In addition, lead 41 is bonded to second patternedportion 18 by a solder, and lead 42 is bonded to second patternedportion 19 by a solder. However, none of thermoelectric conversionelements 20 and support members 30 is mounted on any of first patternedportions 14, 15, 16, 17.

FIG. 2A is a plan view illustrating an arrangement of the group ofelectrodes and other components on first substrate 10.

Electrodes 11 are arranged in a plurality of rows L1, each of whichextends in the Y-axis direction. Bridge electrodes 12 are disposed onthe periphery of first substrate 10 on the negative side of the Y axis,whereas bridge electrodes 13 are disposed on the periphery of firstsubstrate 10 on the positive side of the Y axis. Each of bridgeelectrodes 12 and bridge electrodes 13 is disposed across two adjacentrows L1. Each bridge electrode 12 includes electrode parts 121, 122, and123; the electrode parts 121, 122 are interconnected by electrode part123. Each bridge electrode 12 has notches 124, 125 formed so as toextend, in the Y-axis direction, toward the inner sides of correspondingbridge electrodes 12, in plan view. Notches 124, 125 are each formed onthe line by which two corresponding adjacent rows L1 are separated fromeach other and extend along this line. Likewise, each bridge electrode13 includes electrode parts 131, 132, 133 and notches 134, 135.

First patterned portion 14 is formed on the periphery of the uppersurface of first substrate 10 on the positive side of the Y axis,whereas first patterned portions 15, 16, 17 are formed on the peripheryon the negative side of the Y axis. All of first patterned portions 14,15, 16, 17 extend in the X-axis direction, which is vertical to thedirection in which each of the plurality of rows L1 extends. Secondpatterned portion 18 is formed on the periphery of the upper surface offirst substrate 10 on the positive side of the X axis, whereas secondpatterned portion 19 is formed on the periphery of the upper surface offirst substrate 10 on the negative side of the X axis. Both of secondpatterned portions 18, 19 extend in the Y-axis direction, which isparallel to the direction in which each of the plurality of rows L1extends. Second patterned portion 18 on the right side is integrallyconnected to the rightmost bridge electrode 13, whereas second patternedportion 19 on the left side is integrally connected to the leftmostbridge electrode 13. On the upper surface of first substrate 10, thegroup of electrodes and the group of patterned portions are formedsymmetrically in the X-axis direction.

FIG. 3 is an enlarged view illustrating one corner of the upper surfaceof first substrate 10 on which the group of electrodes are arranged.

As illustrated in FIG. 3, electrode parts 121, 122 in bridge electrode12 have substantially the same thickness as electrodes 11. Electrodepart 123 in bridge electrode 12 has a smaller thickness and a largersurface area than electrodes 11. Electrode parts 121, 122, 123 areformed integrally with one another.

Electrode parts 121, 122 have a somewhat larger square contour thanthermoelectric conversion elements 20, in plan view. Electrode parts121, 122 have the substantially the same size as electrodes 11 in theX-axis direction. Each of electrode part 121 and electrodes 11 arearrayed in the same row. Each of electrode part 122 and electrodes 11are also arrayed in the same row. Further, electrode parts 121, 122 arelinearly arrayed in the X-axis direction with gaps G1 therebetween.

Most areas of electrode parts 123 are formed so as to extend fromcorresponding electrode parts 121 and 122 to the negative side of the Yaxis. The thickness of electrode parts 123 is determined such that theircross-sectional area cut by a plane parallel to the YZ plane and takenalong a straight line S1, by which electrode parts 123 are separatedinto equal halves in the X-axis direction, becomes nearly equal to thecross-sectional area of electrode parts 121 or 122 or electrodes 11which is cut by a plane parallel to the XZ plane. Notches 124, 125 areformed on the corresponding straight line S1. Each of notches 124, 125may have a substantially semicircular shape, in plan view.

As illustrated in FIG. 3, first patterned portions 15, 17 have a littlesmaller thickness than electrode parts 123. First patterned portion 16(see FIG. 2A) has substantially the same thickness as first patternedportions 15, 17. First patterned portions 15, 16, 17 are used to applytensions to first substrate 10 when first substrate 10 is bent in adirection parallel to the XZ plane. Applying tensions to first substrate10 enables first substrate 10 to be bent smoothly in the directionparallel to the XZ plane.

The first patterned portions 15, 16, 17 do not necessarily have to havea smaller thickness than electrode parts 123. Alternatively, the firstpatterned portions 15, 16, 17 may have an arbitrary thickness thatallows predetermined tensions to be applied to first substrate 10.Furthermore, first patterned portions 15, 16, 17 do not necessarily haveto be defined at the locations illustrated in FIGS. 2A and 3.Alternatively, first patterned portions 15, 16, 17 may be formed at anylocations in the X-axis direction. The first patterned portions formedon the periphery of first substrate 10 on the negative side of the Yaxis do not necessarily have to include three first patterned portionsdisposed in the X-axis direction. Alternatively, the first patternedportions may include an arbitrary number of first patterned portions.Moreover, a single first patterned portion may be formed on theperiphery of first substrate 10 on the negative side of the Y axis,similar to first patterned portion 14 formed on the periphery of firstsubstrate 10 on the positive side of the Y axis.

As illustrated in FIG. 3, second patterned portion 19 has substantiallythe same thickness as electrode parts 121, 122 and electrodes 11.Further, second patterned portion 19 has substantially the same size aselectrode parts 121, 122 and electrodes 11 in the X-axis direction. Inaddition to the function of connecting lead 42 to thermoelectricconversion elements 20 as described above (see FIG. 1), second patternedportion 19 functions as a reinforcement member that suppresses firstsubstrate 10 from being easily bent in directions parallel to the YZplane.

In order to cause first substrate 10 to be easily bent in directionsparallel to the YZ plane, it is necessary to decrease the thickness ofsecond patterned portion 19 and increase the size of second patternedportion 19 in the X-axis direction. In this case, the thickness ofsecond patterned portion 19 and the size of second patterned portion 19in the X-axis direction may be adjusted such that the cross-sectionalarea of second patterned portion 19 taken along the plane parallel tothe XZ plane becomes nearly equal to the cross-sectional area ofelectrodes 11 taken along the plane parallel to the XZ plane.

The seven bridge electrodes 13 other than those on the far right andleft sides in the X-axis direction, which are illustrated in FIG. 2A,have substantially the same configuration as bridge electrodes 12illustrated in FIG. 3. The configuration of each of these seven bridgeelectrodes 13 is similar to a configuration that is an inversion, in theY-axis direction, of the configuration of bridge electrodes 12illustrated in FIG. 3. Electrode parts 131 of the seven bridgeelectrodes 13 have substantially the same contour and thickness aselectrode parts 121 of bridge electrodes 12; electrode parts 132 of theseven bridge electrodes 13 have substantially the same contour andthickness as electrode parts 122 of bridge electrodes 12; and electrodeparts 133 of the seven bridge electrodes 13 have substantially the samecontour and thickness as electrode parts 123 of bridge electrodes 12. Apart of the bridge electrode 13 positioned on the far left sideillustrated in FIG. 2A, which corresponds to electrode parts 131 of theseven bridge electrodes 13, is constituted by a part of second patternedportion 19. Likewise, a part of the bridge electrode 13 positioned onthe far right side, which corresponds to electrode parts 132 of theseven bridge electrodes 13, is constituted by a part of second patternedportion 18.

First patterned portion 14 positioned on the positive side of the Y axisillustrated in FIG. 2A has substantially the same thickness and size asfirst patterned portions 15, 17 on the negative side of the Y axisillustrated in FIG. 3. Similar to first patterned portions 15, 17positioned on the negative side of the Y axis, first patterned portion14 positioned on the positive side of the Y axis applies tensions tofirst substrate 10 when first substrate 10 is bent in directionsparallel to the XZ plane. First patterned portion 14 positioned on thepositive side of the Y axis may include a plurality of parts that areseparated from one another in the X-axis direction. Second patternedportion 18 positioned on the positive side of the X axis hassubstantially the same thickness and size as second patterned portion 19positioned on the negative side of the X axis illustrated in FIG. 3.

FIG. 4A is a plan view illustrating an arrangement of thermoelectricconversion elements 20 mounted on the group of electrodes arranged onfirst substrate 10.

P-type of thermoelectric conversion elements 20 and n-typethermoelectric conversion elements 20 are mounted on electrodes 11 in analternate manner in the Y-axis direction. P-type thermoelectricconversion element 20 is mounted on electrode part 131 of bridgeelectrode 13, and n-type thermoelectric conversion element 20 is mountedon electrode part 132 of bridge electrode 13. Thus, p-type and n-typethermoelectric conversion elements 20 are mounted side by side in theX-axis direction on bridge electrode 13. Four support members 30 aremounted on second patterned portion 18, and four support members 30 arealso mounted on second patterned portion 19.

Each thermoelectric conversion element 20 may be substantially cubic inshape. For example, each thermoelectric conversion element 20 may be asemiconductor that converts heat to electricity. Each thermoelectricconversion element 20 may be formed by adding dopant to a material witha great figure of merit Z (=α²/ρK) expressed by Seebeck coefficient α,resistivity ρ, and thermal conductivity K. Examples of this materialinclude a Bi₂Te₃-based material, a lead-tellurium-based material, and asilicon-germanium-based material. By adding different dopants to thematerial, p-type and n-type thermoelectric conversion elements 20 can beindividually formed. For example, antimony (Sb) may be doped to formp-type thermoelectric conversion element 20, and selenium (Se) may bedoped to form n-type thermoelectric conversion element 20. Eachthermoelectric conversion element 20 has electrodes on its upper andlower surfaces, and the electrodes are to be bonded to the group ofelectrodes. Each thermoelectric conversion element 20 may be a Peltierelement or other element that controls heat by using electricity.

Support members 30 have substantially the same shape as thermoelectricconversion elements 20. More specifically, support members 30 may havesubstantially the same height as thermoelectric conversion elements 20.Each support member 30 is preferably made of a highly stiff material.Each support member 30 may be either a p-type or n-type thermoelectricconversion element 20. In this case, the material does not have to bestiff enough for a p-type or n-type thermoelectric conversion element 20and has only to be stiff enough for an assembly. Each support member 30may be made of a material whose upper and lower surfaces can be bondedto patterned portions on first substrate 10 and second substrate 50 by asolder. For example, each support member 30 may be made of a zinc alloy.Each support member 30 may be formed by plating the surface of anassembly made of a metal or resin material. A material for each supportmember 30 preferably has a high wettability for solder.

Each support member 30 may be made of a glass or resin. In this case,the upper and lower surfaces of each support member 30 may be bonded tocorresponding patterned portions on first substrate 10 and secondsubstrate 50 with an adhesive agent, instead of with solder. Thisadhesive agent may be made of an ultraviolet curable resin or athermosetting resin, for example.

Second substrate 50 is attached to the assembly illustrated in FIG. 1from the positive side of the Z axis. A group of electrodes, which areto be bonded to the upper surface of thermoelectric conversion elements20 by a solder, are formed on the negative side of second substrate 50along the Z axis, namely, on the lower surface of second substrate 50.

FIG. 2B is a plan view illustrating an arrangement of a group ofelectrodes on second substrate 50.

Second substrate 50 has substantially the same contour as firstsubstrate 10, in plan view. Second substrate 50 is made of a materialthat is deformable and stretchable in directions parallel to the XYplane. For example, second substrate 50 may be made of a flexible,stretchable resin material.

Electrodes 51, first patterned portions 52, 53, 54, 55, and secondpatterned portions 56, 57 are formed on the negative side of secondsubstrate 50 along the Z axis. Electrodes 51 have substantially the samecontour and thickness as electrodes 11 of first substrate 10. Firstpatterned portion 52 has substantially the same contour and thickness asfirst patterned portion 14. First patterned portion 53 has substantiallythe same contour and thickness as first patterned portion 16. Firstpatterned portion 54 has substantially the same contour and thickness asfirst patterned portion 15. First patterned portion 55 has substantiallythe same contour and thickness as first patterned portion 17. Secondpatterned portion 56 has substantially the same contour and thickness assecond patterned portions 18. Second patterned portion 57 hassubstantially the same contour and thickness as second patternedportions 19.

On first substrate 10, as illustrated in FIG. 2A, seven electrodes 11are arrayed in each row L1 and in the Y-axis direction. On secondsubstrate 50, as illustrated in FIG. 2B, eight electrodes 51 are arrayedin the Y-axis direction and along each of rows corresponding to rows L1.Positions of electrodes 51 disposed on second substrate 50 is shiftedfrom positions of electrodes 11 disposed on first substrate 10 to thepositive side of the Y axis by an amount equal to one half the size ofeach electrode 51 in the Y-axis direction. On second substrate 50,electrodes corresponding to bridge electrodes 12 disposed on firstsubstrate 10 are not formed. Group of electrodes and patterned portionsare disposed on the lower surface of second substrate 50 symmetricallyin the X-axis direction.

FIG. 4B is a plan view illustrating the arrangement of thethermoelectric conversion elements 20, relative to the arrangement ofthe group of electrodes on second substrate 50 when second substrate 50is stacked on the assembly illustrated in FIG. 1.

P-type and n-type thermoelectric conversion elements 20 are alternatelyarranged, in the Y-axis direction, on corresponding electrodes 51 ofsecond substrate 50. Four support members 30 are disposed on secondpatterned portion 56, whereas four support members 30 are disposed onsecond patterned portion 57. When second substrate 50 is stacked on theassembly illustrated in FIG. 1, the upper surfaces of thermoelectricconversion elements 20 are bonded to corresponding electrodes 51 by asolder, and the upper surfaces of support members 30 are bonded toeither one of second patterned portion 56 and second patterned portion57 by a solder.

By stacking second substrate 50 on the assembly illustrated in FIG. 1 inthis manner, p-type and n-type thermoelectric conversion elements 20mounted on first substrate 10 are interconnected in series by the groupof electrodes on first substrate 10 and second substrate 50.

FIG. 5 is a partially enlarged view illustrating the interconnectionsbetween the thermoelectric conversion elements 20 via the group ofelectrodes. In FIG. 5, p-type thermoelectric conversion elements 20 areindividually labeled with the alphabetic character “P”, and n-typethermoelectric conversion elements 20 are individually labeled with thealphabetic character “N”. The broken arrows represent an electricalconnection route. In FIG. 5, support members 30 and second substrate 50are not depicted, for the sake of convenience.

As illustrated in FIG. 5, p-type and n-type thermoelectric conversionelements 20 arrayed in the Y-axis direction are interconnected in seriesby electrodes 11 and electrodes 51. P-type and n-type thermoelectricconversion elements 20 that are positioned on the far negative side ofthe Y axis and arrayed in the X-axis direction are interconnected inseries by bridge electrodes 12. Likewise, p-type and n-typethermoelectric conversion elements 20 that are positioned on the farpositive side of the Y axis and arrayed in the X-axis direction areinterconnected in series by bridge electrodes 13 in first substrate 10(see FIG. 4A).

FIG. 6 is a perspective view illustrating the configuration ofthermoelectric converter 100 in which second substrate 50 is attached tothe assembly illustrated in FIG. 1.

Thermoelectric converter 100 has a square contour with rounded corners,in plan view. Thermoelectric conversion elements 20 are arranged betweenfirst substrate 10 and second substrate 50. The distance between firstsubstrate 10 and second substrate 50 depends on the height ofthermoelectric conversion elements 20 and support members 30 disposedbetween first substrate 10 and second substrate 50. Support members 30are used to reinforce thermoelectric converter 100 in the Z-axisdirection. Leads 41, 42 are drawn from the inner space between firstsubstrate 10 and second substrate 50.

FIG. 7A is a schematic view illustrating thermoelectric converter 100 ina state before thermoelectric converter 100 is mounted on mountingsurface 201 of object 200. FIG. 7B is a schematic view illustratingthermoelectric converter 100 in a state after thermoelectric converter100 is mounted on mounting surface 201 of object 200.

In this exemplary embodiment, the lower surface of first substrate 10functions as functional surface 101. When thermoelectric converter 100is mounted on mounting surface 201 of object 200, the lower surface offirst substrate 10 is brought into contact with mounting surface 201. Inthis case, object 200 is expected to be cylindrical in shape whosecentral axis is parallel to the Y axis. Therefore, mounting surface 201is curved only in a direction parallel to the XZ plane.

When thermoelectric converter 100 that has been in the state illustratedin FIG. 7A is pressed against object 200 with functional surface 101being in contact with mounting surface 201, thermoelectric converter 100is bent at locations P1 in an in-plane direction of the XZ plane. As aresult, as illustrated in FIG. 7B, functional surface 101 ofthermoelectric converter 100 fits mounting surface 201 of object 200.

As explained with reference to FIG. 3, electrode parts 123 of bridgeelectrodes 12 have a smaller thickness and a larger surface area thanelectrodes 11. Likewise, electrode parts 133 of bridge electrodes 13have a smaller thickness and a larger surface area than electrodes 11.Electrode parts 123, 133 configured above help the bending of bridgeelectrodes 12, 13. Consequently, thermoelectric converter 100 can beeasily bent along gaps G1 at positions of gaps G1 each formed betweenadjacent rows L1 and in an in-plane direction of the XZ plane. Thisenables functional surface 101 of thermoelectric converter 100 to easilyfit mounting surface 201 of object 200.

Effect of Embodiment

The above-described exemplary embodiment produces the effects describedbelow.

Electrode parts 123 of bridge electrodes 12 and electrode parts 133 ofbridge electrodes 13 have a smaller thickness and a larger surface areathan electrodes 11. Electrode parts 123, 133 configured above help thebending of bridge electrodes 12, 13. Consequently, thermoelectricconverter 100 can be easily bent along gaps G1 at positions P1 of gapsG1 each formed between adjacent rows L1 and in an in-plane direction ofthe XZ plane. This enables functional surface 101 of thermoelectricconverter 100 to easily fit mounting surface 201 of object 200. Becauseof their large surface area, electrode parts 123 of each bridgeelectrode 12 which have a small thickness can ensure a current densitysubstantially the same as that of electrodes 11. Likewise, because oftheir large surface area, electrode parts 133 of each bridge electrode13 which have a small thickness can ensure a current densitysubstantially the same as that of electrodes 51. Thus, electrode parts123, 133 can produce the substantially the same effect as electrodes 11,51 without affecting performances of thermoelectric converter 100.According to the foregoing exemplary embodiment, when thermoelectricconverter 100 is mounted on cylindrical object 200, functional surface101 can easily fit curved mounting surface 201 without lowingperformances of thermoelectric converter 100.

According to the foregoing exemplary embodiment, electrode parts 121,122 of bridge electrode 12 and electrode parts 131, 132 of bridgeelectrode 13 on which thermoelectric conversion elements 20 are mountedhave substantially the same thickness as electrodes 11. Therefore,thermoelectric conversion elements 20 having the same height can becommonly mounted on all of bridge electrodes 12, 13 and electrodes 11.In other words, thermoelectric conversion elements 20 mounted on bridgeelectrodes 12, 13 do not have to be different in height fromthermoelectric conversion elements 20 mounted on electrodes 11.Consequently, it is possible to mount thermoelectric conversion elements20 on bridge electrodes 12, 13 and electrodes 11 with efficiency.

According to the foregoing exemplary embodiment, each bridge electrode12 has notches 124, 125, and each bridge electrode 13 has notches 134,135. Each of the notches 124, 125 is formed on a line by which twoadjacent rows L1 are separated from each other and which extends alongthis line and toward the inner side of bridge electrode 12. Each of thenotches 134, 135 is formed on a line by which two adjacent rows L1 areseparated from each other and which extends along this line and towardthe inner side of bridge electrode 13. Forming notches 124, 125, 134,135 in this manner helps the bending of electrode parts 123, 133.Consequently, thermoelectric converter 100 can be more easily bent,thereby causing functional surface 101 to more easily fit mountingsurface 201 of object 200.

According to the foregoing exemplary embodiment, first patternedportions 14, 15, 16, 17, none of which is bonded to any ofthermoelectric conversion elements 20, are formed on both peripheries offirst substrate 10 in the Y-axis direction so as to extend in adirection vertical to rows L1. Likewise, first patterned portions 52,53, 54, 55 are formed on both peripheries of second substrate 50 in theY-axis direction. Forming first patterned portions 14, 15, 16, 17, 52,53, 54, 55 in this manner makes it possible to apply desired tensions tothermoelectric converter 100 when thermoelectric converter 100 is bent.As a result, both first substrate 10 and second substrate 50 are bentsmoothly in a direction parallel to the XZ plane. This enablesfunctional surface 101 of thermoelectric converter 100 to fit moresmoothly mounting surface 201 of object 200.

According to the foregoing exemplary embodiment, second patternedportions 18, 19, none of which is bonded to any of thermoelectricconversion elements 20, are formed on both peripheries of firstsubstrate 10 in the X-axis direction so as to extend in a directionparallel to rows L1. Likewise, second patterned portions 56, 57 areformed on both peripheries of second substrate 50 in the X-axisdirection. Forming second patterned portions 18, 19, 56, 57 in thismanner suppresses thermoelectric converter 100 from being bent indirections parallel to the YZ plane. This makes it possible tofacilitate a process for causing functional surface 101 ofthermoelectric converter 100 to fit mounting surface 201 of object 200.

Lead 41 is connected to second patterned portion 18 and furtherelectrically connected to thermoelectric conversion elements 20 viasecond patterned portion 18, and lead 42 is connected to secondpatterned portion 19 and further electrically connected tothermoelectric conversion elements 20 via second patterned portion 19.In this way, second patterned portions 18, 19 can be used both tosuppress thermoelectric converter 100 from being bent and to introduceleads 41, 42 into thermoelectric converter 100 as described above. Thisstructure contributes to downsizing of thermoelectric converter 100.

Variation

In the foregoing exemplary embodiment, electrodes 51 are formed onsecond substrate 50. When second substrate 50 is stacked on the uppersurfaces of thermoelectric conversion elements 20, electrodes 51 arebonded to the upper surfaces of thermoelectric conversion elements 20 bya solder. However, electrodes 51 do not necessarily have to be mountedon second substrate 50. Alternately, electrodes 51 may be prospectivelybonded to the upper surfaces of thermoelectric conversion elements 20 bya solder.

FIG. 8 is a perspective view illustrating an exemplary configuration ofthermoelectric converter 100 according to a variation of the exemplaryembodiment, from which second substrate 50 is removed. In thisvariation, as illustrated in FIG. 8, electrodes 51 are prospectivelybonded to the upper surfaces of thermoelectric conversion elements 20 bya solder before second substrate 50 is attached to first substrate 10.In this variation illustrated in FIG. 8, second patterned portions 56,57 are also prospectively bonded to the upper surface of support member30 by a solder. In FIG. 8, the portions of second patterned portions 56,57 indicated by broken lines are not depicted, for the sake ofconvenience.

In this variation, second substrate 50 is not provided with electrode 51and second patterned portions 56, 57. In addition, second substrate 50does not necessarily have to be provided with first patterned portions52, 53, 54.

When second substrate 50 is stacked on the upper surface of the assemblyillustrated in FIG. 8, for example, second substrate 50 may be fixed tothe upper surface of second patterned portion 57 positioned on thepositive side of the X axis with an adhesive agent. More specifically,the periphery of second substrate 50 on the positive side of the X axisis fixed to the upper surface of second patterned portion 57 inthermoelectric converter 100 assembled as illustrated in FIG. 6, but theremaining part of second substrate 50 is not fixed to, namely, free fromthe upper surfaces of electrodes 51 and second patterned portion 56positioned on the negative side of the X axis.

In this variation, except for the periphery on the one side, secondsubstrate 50 is free from the upper surfaces of electrodes 51 and secondpatterned portion 56 positioned on the negative side of the X axis.Therefore, thermoelectric converter 100 according to this variation canbe more easily bent in an in-plane direction of the XZ plane in FIG. 6than thermoelectric converter 100 according to the foregoing exemplaryembodiment. Consequently, when functional surface 101 is pressed againstmounting surface 201 as illustrated in FIG. 7B, thermoelectric converter100 is more easily bent, and accordingly, functional surface 101 fitsmounting surface 201 more smoothly.

In this variation, there is a risk that second substrate 50 is separatedfrom the upper surfaces of electrodes 51 in the state illustrated inFIG. 7B. In this variation, therefore, when thermoelectric converter 100is mounted on object 200, thermoelectric converter 100 may be fixed toobject 200 by an attachment, and then the upper surface of secondsubstrate 50 may be pressed against object 200 with this attachment.This can reduce the risk of second substrate 50 being separated from theupper surfaces of electrodes 51.

In this variation, second substrate 50 is bonded to the upper surface ofsecond patterned portion 57 with an adhesive agent. Alternatively, byapplying an insulating grease to the upper surfaces of electrode 51 andsecond patterned portions 56, 57, second substrate 50 may be temporarilyfixed to the upper surfaces of electrodes 51 and second patternedportions 56, 57 with an adhesive force of the insulating grease.

In the above case, second substrate 50 is displaceable from the uppersurfaces of electrode 51 and second patterned portions 56, 57 indirections parallel to the XY plane. Therefore, thermoelectric converter100 according to this variation can be more easily bent in an in-planedirection of the XZ plane in FIG. 6 than thermoelectric converter 100according to the foregoing exemplary embodiment. Consequently, whenfunctional surface 101 is pressed against mounting surface 201 asillustrated in FIG. 7B, thermoelectric converter 100 is more easilybent, and accordingly, functional surface 101 fits mounting surface 201more smoothly.

In the foregoing exemplary configuration illustrated in FIG. 8, secondpatterned portions 56, 57 are disposed on the upper surfaces of supportmembers 30. However, none of second patterned portions 56, 57 may bedisposed thereon. Furthermore, second substrate 50 may be temporarilyfixed to the upper surfaces of electrodes 51 and second patternedportions 56, 57 with friction between electrodes 51 and second substrate50, instead of with grease or an adhesive agent.

In the foregoing exemplary embodiment, support members 30 are disposedbetween first substrate 10 and second substrate 50 together withthermoelectric conversion elements 20. However, support members 30 maybe optional components. None of support members 30 may be disposed ifthermoelectric converter 100 can ensure a sufficient strength in theZ-axis direction.

In the foregoing exemplary embodiment, first patterned portions 52, 53,54, 55 are provided in second substrate 50. However, none of firstpatterned portions 52, 53, 54, 55 may be provided in second substrate 50if thermoelectric converter 100 can be bent sufficiently smoothly.Alternately, first patterned portions 52, 53, 54, 55 may be provided insecond substrate 50, but none of first patterned portions 14, 15, 16, 17may be provided in first substrate 10. This means that first patternedportions 14, 15, 16, 17 and first patterned portions 52, 53, 54, 55 maybe optional components. None of first patterned portions 14, 15, 16, 17and first patterned portions 52, 53, 54, 55 may be provided iffunctional surface 101 can fit the mounting surface sufficientlysmoothly.

In the foregoing exemplary embodiment, second patterned portions 56, 57are provided in second substrate 50. However, none of second patternedportions 56, 57 may be provided in second substrate 50 if it is possibleto control the bending of thermoelectric converter 100 in directionsparallel to the YZ plane. Furthermore, by decreasing the thicknesses ofsecond patterned portions 18, 19 on first substrate 10 and secondpatterned portions 56, 57 on second substrate 50, as described above,thermoelectric converter 100 may be more easily bent or deformed indirections parallel to the YZ plane. Alternatively, by not providingsecond patterned portions 18, 19 on first substrate 10 and secondpatterned portions 56, 57 on second substrate 50, thermoelectricconverter 100 may be more easily bent or deformed in directions parallelto the YZ plane. If second patterned portions 18, 19, 56, 57 are notprovided, for example, leads 41, 42 may be connected to bridgeelectrodes 13 on the far right and left sides illustrated in FIG. 2A. Inthis case, bridge electrodes 13 on the far right and left sides may havesubstantially the same thickness and area as electrodes 11.

In the foregoing exemplary embodiment, as illustrated in FIG. 3, thethickness of electrode parts 121, 122 is set to be substantially thesame as the thickness of electrodes 11. However, the thickness ofelectrode parts 121, 122 may be set to be substantially the same as thethickness of electrode parts 123. In this case, since the thickness ofelectrode parts 121, 122 may be smaller than the thickness of electrodes11, thermoelectric conversion elements 20 mounted on electrode parts121, 122 need to be positioned at a height greater than thermoelectricconversion elements 20 mounted on electrode 11 by an amount equal to thedifference in thickness. As a result, thermoelectric conversion elements20 having different sizes need to be mounted on electrodes 11 and bridgeelectrodes 12. This may result in decreased productivity. Thus, in orderto mount thermoelectric conversion elements 20 with efficiency, thethickness of electrode parts 121, 122 may be preferably set tosubstantially the same as the thickness of electrodes 11.

In the foregoing exemplary embodiment, the group of electrodes are laidout such that all of bridge electrodes 12, 13 are disposed on firstsubstrate 10. However, the group of electrodes may be laid out such thatbridge electrodes 12 or 13 or all of bridge electrodes 12, 13 aredisposed on second substrate 50. Moreover, the contours of electrodes 11and bridge electrodes 12, 13 and the areas and contours of electrodeparts 123, 133 in plan view may also be modified as appropriate.

In addition to the above, the exemplary embodiment of the presentdisclosure may be modified as appropriate in various ways within thescope of the technical idea described in the claims.

What is claimed is:
 1. A thermoelectric converter comprising: a firstsubstrate being capable to deform; a second substrate being capable todeform; a plurality of thermoelectric conversion elements disposedbetween the first substrate and the second substrate; and a group ofelectrodes that electrically interconnect the plurality ofthermoelectric conversion elements by solder bonding the plurality ofthermoelectric conversion elements to the group of electrodes,respectively, wherein: the plurality of thermoelectric conversionelements are arranged in a plurality of rows including a first row and asecond row, the first row being adjacent to the second row, theplurality of rows extending in an extending direction identical to eachother, the group of electrodes includes a first electrode and a secondelectrode having a different shape from the first electrode, the firstelectrode electrically interconnecting between two of the plurality ofthermoelectric conversion elements in the first row, the secondelectrode electrically interconnecting between one of the plurality ofthermoelectric conversion elements in the first row and one of theplurality of thermoelectric conversion elements in the second row, thesecond electrode includes a first notch disposed on a first edge of thesecond electrode and a second notch disposed on a second edge of thesecond electrode, the first notch and the second notch are arranged in aline extending between the first row and the second row, the first notchis disposed in a first region sandwiched between a first part of thesecond electrode and a second part of the second electrode in plan view,the second notch is disposed in a second region opposite to the firstregion in plan view, the one of the plurality of thermoelectricconversion elements in the first row is disposed on the first part ofthe second electrode, the one of the plurality of thermoelectricconversion elements in the second row is disposed on the second part ofthe second electrode, and a notched area of the first notch is largerthan a notched area of the second notch in plan view.
 2. Thethermoelectric converter according to claim 1, wherein each of the firstnotch and the second notch has a substantially semicircular shape at apart facing each other in plan view.